Papermaking Belts for Making Fibrous Structures

ABSTRACT

A papermaking belt can have a reinforcing element with a surface and a plurality of discrete knuckles extending from portions of the surface. The plurality of discrete knuckles can be arranged in a pattern of repeat units, and each of the discrete knuckles within the repeat unit can have substantially the same shape and size. At least some of the discrete knuckles can be arranged in a plurality of rows of adjacent knuckles separated by a distance, including at least a first row and a second row. The distance between at least two adjacent discrete knuckles in the first row can be different than the distance between at least two adjacent discrete knuckles in the second row.

FIELD

The present disclosure generally relates to papermaking belts for makingfibrous structures and, more particularly, relates to papermaking beltsfor making fibrous structures comprising discrete elements situated inirregular patterns.

BACKGROUND

Fibrous structures, such as sanitary tissue products, for example, areuseful in many ways in everyday life. These products can be used aswiping implements for post-urinary and post-bowel movement cleaning(toilet tissue and wet wipes), for otorhinolaryngological discharges(facial tissue), and multi-functional absorbent and cleaning uses (papertowels).

Retail consumers fibrous structures such as paper towels and bath tissuelook for certain properties, including softness, strength, andabsorbency, for example. Such properties can be supplied in a fibrousstructure by the selection of the material components of the fibrousstructure and the manufacturing equipment and processes used to make it.

However, also important in today's retail environment is the appearanceof a paper towel or bath tissue. That is, in addition to superiorperformance properties of a fibrous structure, retail consumers desirethe product to be visually appealing. Thus, manufacturers of fibrousstructures such as paper towels and bath tissue must produce productsthat both perform well, and have consumer-acceptable aestheticqualities.

Often the two goals of superior product performance and desirableaesthetics are in contradiction to one another. For example, absorbencyor strength in a paper towel can depend on processing parameters such asthe structure of papermaking belts during paper making or the embosspattern applied during converting operations. Both paper structuresproduced during papermaking and embossing can affect the physicalproperties of the finished product, but they also affect the visual,aesthetic properties. It can happen that a fibrous structure in the formof a paper towel, for example, can have superior absorbency propertiesin a visually un-aesthetic manner.

The existing art can be improved, and the consumer desired results canbe achieved, by new fibrous structures that deliver both superiorperformance properties and consumer-desirable aesthetic properties.

SUMMARY

A papermaking belt can have a reinforcing element with a surface and aplurality of discrete knuckles extending from portions of the surface.The plurality of discrete knuckles can be arranged in a pattern ofrepeat units, and each of the discrete knuckles within the repeat unitcan have substantially the same shape and size. At least some of thediscrete knuckles can be arranged in a plurality of rows of adjacentknuckles separated by a distance, including at least a first row and asecond row. The distance between at least two adjacent discrete knucklesin the first row can be different than the distance between at least twoadjacent discrete knuckles in the second row.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of the presentdisclosure, and the manner of attaining them, will become more apparentand the disclosure itself will be better understood by reference to thefollowing description of non-limiting embodiments of the disclosuretaken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a representative papermaking belt of the kind useful as apapermaking belt used in the present invention;

FIG. 2 is a photograph of a portion of a paper towel product marketed byThe Procter & Gamble Co.;

FIG. 3 is a plan view of a mask used to make the papermaking belt thatproduced the paper towel of FIG. 2;

FIG. 4 is a photograph of a portion of a fibrous structure product ofthe present invention;

FIG. 5 is a plan view of a repeat pattern for a mask used to make thepapermaking belt that produced the fibrous structure of FIG. 4;

FIG. 6 is representation of how patterns of cells can be oriented in thepresent invention;

FIG. 7 shows two repeat units for a pattern for a mask used to make thepapermaking belt that produced the fibrous structure of FIG. 4;

FIG. 8 is a photograph of a fibrous structure product of the presentinvention;

FIG. 9 is a plan view of a repeat unit of a mask used to make thepapermaking belt that produced the fibrous structure of FIG. 8;

FIG. 10 is a photograph of a fibrous structure product of the presentinvention;

FIG. 11 is a plan view of a repeat unit of a mask used to make thepapermaking belt that produced the fibrous structure of FIG. 10;

FIG. 12 is a plan view of an alternative repeat unit of a mask suitablefor making a papermaking belt to produce a fibrous structure of thepresent invention; and

FIG. 13 is a schematic representation of one method for making a fibrousstructure of the present invention.

DETAILED DESCRIPTION

Various non-limiting embodiments of the present disclosure will now bedescribed to provide an overall understanding of the principles of thestructure, function, manufacture, and use of the papermaking belt formaking fibrous structures disclosed herein. One or more examples ofthese non-limiting embodiments are illustrated in the accompanyingdrawings. Those of ordinary skill in the art will understand that thepapermaking belts and fibrous structures described herein andillustrated in the accompanying drawings are non-limiting exampleembodiments and that the scope of the various non-limiting embodimentsof the present disclosure are defined solely by the claims. The featuresillustrated or described in connection with one non-limiting embodimentcan be combined with the features of other non-limiting embodiments.Such modifications and variations are intended to be included within thescope of the present disclosure.

Fibrous structures such as paper towels, bath tissues and facial tissuesare typically made in a “wet laying” process in which a slurry offibers, usually wood pulp fibers, is deposited a onto a forming wireand/or one or more papermaking belts such that an embryonic fibrousstructure can be formed, after which drying and/or bonding the fiberstogether results in a fibrous structure. Further processing the fibrousstructure can be carried out such that a finished fibrous structure canbe formed. For example, in typical papermaking processes, the finishedfibrous structure is the fibrous structure that is wound on the reel atthe end of papermaking, and can subsequently be converted into afinished product (e.g., a sanitary tissue product) by ply-bonding andembossing, for example.

The wet-laying process can be designed such that the finished fibrousstructure has visually distinct features produced in the wet-layingprocess. Any of the various forming wires and papermaking belts utilizedcan be designed to leave a physical, three-dimensional impression in thefinished paper. Such three-dimensional impressions are well known in theart, particularly in the art of “through air drying” (TAD) processes,with such impressions often being referred to a “knuckles” and“pillows.” Knuckles are typically relatively high density regionscorresponding to the “knuckles” of a papermaking belt, i.e., thefilaments or resinous structures that are raised at a higher elevationthan other portions of the belt. Likewise, “pillows” are typicallyrelatively low density regions formed in the finished fibrous structureat the relatively uncompressed regions between or around knuckles.Further, the pillows in a fibrous structure can exhibit a range ofdensities relative to one another.

Thus, in the description below, the term “knuckles” or “knuckle region,”or the like can be used for either the raised portions of a papermakingbelt or the densified, raised portions formed in the paper made on thepapermaking belt, and the meaning should be clear from the context ofthe description herein. Likewise “pillow” or “pillow region” or the likecan be used for either the portion of the papermaking belt between oraround knuckles (also referred to herein and in the art as “deflectionconduits” or “pockets”), or the relatively uncompressed regions betweenor around knuckles in the paper made on the papermaking belt, and themeaning should be clear from the context of the description herein.Knuckles or pillows can each be either continuous or discrete, asdescribed herein.

Knuckles and pillows in paper towels and bath tissue can be visible tothe retail consumer of such products. The knuckles and pillows can beimparted to a fibrous structure from a papermaking belt in variousstages of production, i.e., at various consistencies and at various unitoperations during the drying process, and the visual pattern generatedby the pattern of knuckles and pillows can be designed for functionalperformance enhancement as well as to be visually appealing. Suchpatterns of knuckles and pillows can be made according to the methodsand processes described in U.S. Pat. No. 6,610,173, issued to Lindsay etal. on Aug. 26, 2003, or U.S. Pat. No. 4,514,345 issued to Trokhan onApr. 30, 1985, or U.S. Pat. No. 6,398,910 issued to Burazin et al. onJun. 4, 2002, or US Pub. No. 2013/0199741; published in the name ofStage et al. on Aug. 8, 2013. The Lindsay, Trokhan, Burazin and Stagedisclosures describe belts that are representative of papermaking beltsmade with cured resin on a woven reinforcing member, of which thepresent invention is an improvement. But further, the presentimprovement can be utilized as a fabric crepe belt as disclosed in U.S.Pat. No. 7,494,563, issued to Edwards et al. on Feb. 24, 2009 or U.S.Pat. No. 8,152,958, issued to Super et al. on Apr. 10, 2012, as well asbelt crepe belts, as described in U.S. Pat. No. 8,293,072, issued toSuper et al on Oct. 23, 2012. When utilized as a fabric crepe belt, apapermaking belt of the present invention can provide the relativelylarge recessed pockets and sufficient knuckle dimensions to redistributethe fiber upon high impact creping in a creping nip between a backingroll and the fabric to form additional bulk in conventional wet pressprocesses. Likewise, when utilized as a belt in a belt crepe method, apapermaking belt of the present invention can provide the fiber enricheddome regions arranged in a repeating pattern corresponding to thepattern of the papermaking belt, as well as the interconnected pluralityof surround areas to form additional bulk and local basis weightdistribution in a conventional wet press process.

An example of a papermaking belt structure of the type useful in thepresent invention and made according to the disclosure of U.S. Pat. No.4,514,345 is shown in FIG. 1. As shown, the papermaking belt 2 caninclude cured resin elements 4 forming knuckles 20 on a wovenreinforcing member 6. The reinforcing member 6 can made of wovenfilaments 8 as is known in the art of papermaking belts, including resincoated papermaking belts. The papermaking belt structure shown in FIG. 1includes discrete knuckles 20 and a continuous deflection conduit, orpillow region. The discrete knuckles 20 can form densified knuckles inthe fibrous structure made thereon; and, likewise, the continuousdeflection conduit, i.e., pillow region, can form a continuous pillowregion in the fibrous structure made thereon. The knuckles can bearranged in a pattern described with reference to an X-Y plane, and thedistance between knuckles 20 in at least one of X or Y directions canvary according to the present invention disclosed herein.

A second way to provide visually perceptible features to a fibrousstructure like a paper towel or bath tissue is embossing. Embossing is awell known converting process in which at least one embossing rollhaving a plurality of discrete embossing elements extending radiallyoutwardly from a surface thereof can be mated with a backing, or anvil,roll to form a nip in which the fibrous structure can pass such that thediscrete embossing elements compress the fibrous structure to formrelatively high density discrete elements in the fibrous structure whileleaving uncompressed, or substantially uncompressed, relatively lowdensity continuous or substantially continuous network at leastpartially defining or surrounding the relatively high density discreteelements.

Embossed features in paper towels and bath tissues can be visible to theretail consumer of such products. As a result, the visual patterngenerated by the pattern of knuckles and pillows can be designed to bevisually appealing. Such patterns are well known in the art, and can bemade according to the methods and processes described in US Pub. No. US2010-0028621 A1 in the name of Byrne et al. or US 2010-0297395 A1 in thename of Mellin, or U.S. Pat. No. 8,753,737 issued to McNeil et al. onJun. 17, 2014.

In an embodiment, a fibrous structure of the present invention has apattern of knuckles and pillows imparted to it by a papermaking belthaving a corresponding pattern of knuckles and pillows that provides forsuperior product performance and is visually appealing to a retailconsumer.

In an embodiment, a fibrous structure of the present invention has apattern of knuckles and pillows imparted to it by a papermaking belthaving a corresponding pattern of knuckles and an emboss pattern, whichtogether with the knuckles and pillows provides for an overall visualappearance that is appealing to a retail consumer.

In an embodiment, a fibrous structure of the present invention has apattern of knuckles and pillows imparted to it by a papermaking belthaving a corresponding pattern of knuckles, an emboss pattern, whichtogether with the knuckles and pillows provides for an overall visualappearance that is appealing to a retail consumer, and exhibits superiorproduct performance over known fibrous structures.

“Fibrous structure” as used herein means a structure that comprises oneor more fibers. Paper is a fibrous structure. Nonlimiting examples ofprocesses for making fibrous structures include known wet-laidpapermaking processes and air-laid papermaking processes, and embossingand printing processes. Such processes typically comprise the steps ofpreparing a fiber composition in the form of a suspension in a medium,either wet, more specifically aqueous medium, or dry, more specificallygaseous (i.e., with air as medium). The aqueous medium used for wet-laidprocesses is oftentimes referred to as a fiber slurry. The fibroussuspension is then used to deposit a plurality of fibers onto a formingwire or papermaking belt such that an embryonic fibrous structure can beformed, after which drying and/or bonding the fibers together results ina fibrous structure. Further processing the fibrous structure can becarried out such that a finished fibrous structure can be formed. Forexample, in typical papermaking processes, the finished fibrousstructure is the fibrous structure that is wound on the reel at the endof papermaking, and can subsequently be converted into a finishedproduct (e.g., a sanitary tissue product).

The fibrous structures of the present disclosure can exhibit a basisweight of greater than about 15 g/m² (9.2 lbs/3000 ft²) to about 120g/m² (73.8 lbs/3000 ft²), alternatively from about 15 g/m² (9.2 lbs/3000ft²) to about 110 g/m² (67.7 lbs/3000 ft²), alternatively from about 20g/m² (12.3 lbs/3000 ft²) to about 100 g/m² (61.5 lbs/3000 ft²), andalternatively from about 30 g/m² (18.5 lbs/3000 ft²) to about 90 g/m²(55.4 lbs/3000 ft²). In addition, the sanitary tissue products and/orthe fibrous structures of the present disclosure can exhibit a basisweight between about 40 g/m² (24.6 lbs/3000 ft²) to about 120 g/m² (73.8lbs/3000 ft²), alternatively from about 50 g/m² (30.8 lbs/3000 ft²) toabout 110 g/m² (67.7 lbs/3000 ft²), alternatively from about 55 g/m²(33.8 lbs/3000 ft²) to about 105 g/m² (64.6 lbs/3000 ft²), andalternatively from about 60 g/m² (36.9 lbs/3000 ft²) to about 100 g/m²(61.5 lbs/3000 ft²).

The fibrous structures of the present disclosure can exhibit a density(measured at 95 g/in²) of less than about 0.60 g/cm³, alternatively lessthan about 0.30 g/cm³, alternatively less than about 0.20 g/cm³,alternatively less than about 0.10 g/cm³, alternatively less than about0.07 g/cm³, alternatively less than about 0.05 g/cm³, alternatively fromabout 0.01 g/cm³ to about 0.20 g/cm³, and alternatively from about 0.02g/cm³ to about 0.10 g/cm³.

The fibrous structures of the present disclosure can be in the form ofsanitary tissue product rolls. Such sanitary tissue product rolls cancomprise a plurality of connected, but perforated sheets of one or morefibrous structures, that are separably dispensable from adjacent sheets,such as is known for paper towels and bath tissue, which are bothconsidered sanitary tissue products when in roll form.

The fibrous structures of the present disclosure can comprises additivessuch as softening agents, temporary wet strength agents, permanent wetstrength agents, bulk softening agents, lotions, silicones, wettingagents, latexes, especially surface-pattern-applied latexes, drystrength agents such as KYMENE® wet strength additive,polyamido-amine-epichlorhydrin (PAE), carboxymethylcellulose and starch,and other types of additives suitable for inclusion in and/or onsanitary tissue products and/or fibrous structures.

“Machine Direction” or “MD” as used herein means the direction on a webcorresponding to the direction parallel to the flow of a fibrous web orfibrous structure through a fibrous structure making machine. “CrossMachine Direction” or “CD” as used herein means a directionperpendicular to the Machine Direction in the plane of the web.

“Relatively low density” as used herein means a portion of a fibrousstructure having a density that is lower than a relatively high densityportion of the fibrous structure. The relatively low density can be inthe range of 0.02 g/cm³ to 0.09 g/cm³, for example relative to a highdensity that can be in the range of 0.1 to 0.13 g/cm³.

“Relatively high density” as used herein means a portion of a fibrousstructure having a density that is higher than a relatively low densityportion of the fibrous structure. The relatively high density can be inthe range of 0.1 to 0.13 g/cm³, for example, relative to a low densitythat can be in the range of 0.02 g/cm³ to 0.09 g/cm³. “Substantiallycontinuous” as used herein with respect to high or low density networksmeans the network fully defines or surrounds more of the discretedeflection cells than it partially defines or surrounds. Thesubstantially continuous member can be interrupted by macro patternsformed in the papermaking belt, as disclosed in U.S. Pat. No. 5,820,730issued to Phan et al. on Oct. 13, 1998.

“Substantially continuous deflection conduit” is also referred to a“substantially continuous pillow” and as used herein means a portion ofa papermaking belt or fibrous structure that at least partially definesor surrounds a plurality of knuckles, i.e., discrete portions raisedfrom a papermaking belt or fibrous structure. The substantiallycontinuous conduit will fully define or surround more of the knucklesthan it partially defines or surrounds. The substantially continuousdeflection conduit can be interrupted by macro patterns formed in thepapermaking belt.

“Discrete deflection cell” also referred to a “discrete pillow” and asused herein means a portion of a papermaking belt or fibrous structuredefined or surrounded by, or at least partially defined or surroundedby, a substantially continuous knuckle portion, i.e., a substantiallycontinuous network of raised portions on a papermaking belt or fibrousstructure.

“Discrete raised portion” as used herein means a discrete knuckle, i.e.,a portion of a papermaking belt or fibrous structure defined orsurrounded by, or at least partially defined or surrounded by, asubstantially continuous deflection conduit or relatively low densitypillow region that has an enclosed perimeter.

Fibrous Structures

The fibrous structures of the present disclosure can be single-ply ormulti-ply fibrous structures and can comprise cellulosic pulp fibers.Other naturally-occurring and/or non-naturally occurring fibers can alsobe present in the fibrous structures. In one example, the fibrousstructures can be throughdried in a TAD process, thus producing what isreferred to as “TAD paper”. The fibrous structures can be wet-laidfibrous structures and can be incorporated into single- or multi-plysanitary tissue products.

The fibrous structures of the invention will be described in the contextof paper towels, and in the context of a papermaking belt comprisingcured resin on a woven reinforcing member. However, the invention is notlimited to paper towels and can be made in other known processes thatimpart the knuckles and pillow patterns describe herein, including, forexample, the fabric crepe and belt crepe processes described above,modified as described herein to produce the papermaking belts and paperof the invention.

In general, the fibrous structure, e.g., paper towel, of the inventioncan be made in a process utilizing a papermaking belt that has a patternof resin cured knuckles on a woven reinforcing member, of the typedescribed in reference to FIG. 1. The resin is cured in a patterndictated by a patterned mask having opaque regions and transparentregions. The transparent regions permit curing radiation to penetrate tocure the resin, while the opaque regions prevent the curing radiationfrom curing portions of the resin. Once curing is achieved, the uncuredresin is washed away to leave a pattern of cured resin that issubstantially identical to the mask pattern. The cured portions are theknuckles of the belt, and the uncured portions are the pillows ordeflection conduits of the papermaking belt. Thus, the mask pattern isreplicated in papermaking belt, which pattern is essentially replicatedin the fibrous structure. Therefore, in describing the pattern ofknuckles and pillows in the fibrous structure of the invention, thepattern of the mask can serve as a proxy, and in the description below avisual description of the mask may be provided, and one is to understandthat the dimensions and appearance of the mask is essentially identicalto the dimensions and appearance of the papermaking belt made by themask, and the fibrous structure made on the papermaking belt. Further,in processes that use a papermaking belt not made from a mask, theappearance and structure of the papermaking belt in the same way isimparted to the paper, such that the dimensions of features on thepapermaking belt can also be measured and characterized as a proxy forthe dimensions and characteristics of the finished paper.

FIG. 2 illustrates a portion of a sheet on a roll 10 of sanitary tissue12 currently marketed by The Procter & Gamble Co. as BOUNTY® papertowels. FIG. 3 shows the mask 14 used to make the papermaking belt (notshown, but of the type shown in FIG. 1, having the pattern of knucklescorresponding to the mask of FIG. 3) that made the sanitary tissue 12shown in FIG. 4. As shown, the sanitary tissue exhibits a pattern ofknuckles 20 which were formed by discrete cured resin knuckles on thepapermaking belt, and which correspond to the black areas, referred toas cells 24 of the mask shown in FIG. 3. Any portion of the pattern ofFIG. 3 that is black represents a transparent region of the mask, whichpermits UV-light curing of UV-curable resin to form a knuckle on thepapermaking belt. Likewise, each knuckle on the papermaking belt forms aknuckle 20 in sanitary tissue 12, which can be a relatively high densityregion or a region of different basis weight relative to the pillowregions. Any portion of the pattern of FIG. 4 that is white representsan opaque region of the mask, which blocks UV-light curing of theUV-curable resin. The uncured resin is ultimately washed away to form adeflection conduit on the papermaking belt, which can form a relativelylow density pillow 22 in the fibrous structure.

In embodiments of fibrous structures using belts formed by masks thatdictate the eventual relative densities of the discrete elements andcontinuous elements of fibrous structures, such as the one shown in FIG.3, the relative densities can be inverted such that the fibrousstructure has relatively low density areas where relatively high densityareas are (in FIG. 3) and, similarly, relatively high density areaswhere relatively low density areas are (in FIG. 3). As can be understoodby the description herein, the inverse relationship can be achieved byinverting the black and white (or, more generally, the opaque andtransparent) portions of the mask used to make the belt that is used tomake the fibrous structure. This inverse relation (black/white) canapply to all patterns of the present disclosure, although all fibrousstructures/patterns of each category are not illustrated for brevitysince the concept is illustrated in FIGS. 2 and 3. The papermaking beltsof the present disclosure and the process of making them are describedin further detail below.

The BOUNTY® paper towel shown in FIG. 2 has enjoyed tremendous marketsuccess. The product's performance together with its aesthetic visualappearance has proven to be very desirable to retail consumers. Thevisual appearance is due to the pattern of knuckles 20 and pillows 22and the pattern of embossments 30. As shown, the BOUNTY® paper towel hasboth line embossments 32 and “dot” embossments 34. The pattern ofknuckles 20 and pillows 22 can be considered to be a “wet-formed”background pattern, with the pattern of embossments 30 overlaid thereonbeing considered “dry-formed”. Thus, the pattern of knuckles and pillowsand the embossments together give the paper towel its visual appearance.

The BOUNTY® paper towel shown in FIG. 2 will be used to contrast thedisclosed embodiments of the invention, as it serves as benchmark todescribe inventive improvements in the field. Thus, the presentinvention represents an improvement over current technology, includingthat utilized for current BOUNTY® paper towels, and the improvements aredescribed below with respect to key differences. The key differences arealso shown in table form in Table 1, below.

TABLE 1 Comparison of in-market product and embodiments of the inventionSUBSTRATE PERFORMANCE Absorb- Flexural PATTERN DESCRIPTION encyRigidity/ CELL CELL CELL SIZE CELL LOCATION Rate Total Dry DESIGN SHAPEORIENTATION KNUCKLE PILLOW UNIFORM RANDOM ( g/sec^(1/2)) Tensile InMarket CONSTANT CONSTANT VARYING CONSTANT X 1.65 0.40 Bounty INVEN-CONSTANT CONSTANT CONSTANT VARYING 1D 2.1 0.51 TION 1 INVEN- CONSTANTCONSTANT VARYING VARYING 2D 1.97 0.47 TION 2 INVEN- CONSTANT CONSTANTCONSTANT VARYING X 1.91 0.48 TION 3

As used in Table 1, the term “cell” is used to represent the discreteelement of a mask, belt, or fibrous structure. Thus, as illustratedherein, the term cell can represent discrete black (transparent)portions of a mask, a discrete resinous element on a papermaking belt,or a discrete relatively high or low density portion of a fibrousstructure. In terms of dimensions, including relative size and spacing,the three are substantially exact, or close approximations of oneanother. In the description herein, the schematic representation ofcells 24 can be considered representations of a discrete element of oneor more transparent portions of a mask, one or more knuckles on apapermaking belt, or one or more knuckles in a fibrous structure. Butthe invention is not limited to one method of making, so the term cellcan refer to a discrete feature such as a raised element, a dome-shapedelement or knuckle formed by belt or fabric creping on a fibrousstructure, for example.

Table 1 further records the cell size and spacing characteristics forthe current BOUNTY® paper towel and embodiments of the invention. ForBOUNTY® and the embodiments of the invention shown in Table 1, the cellsare knuckles of a sanitary tissue. That is, the fibrous structures madein the present invention recorded in Table 1 each exhibit a structure ofdiscrete knuckles and a continuous pillow region. Therefore, Table 1records cell sizes as the area of the knuckles when viewed in plan viewand cell spacing in terms of the distances between adjacent knuckles, asdescribed below. In general, the knuckle area of each cell can beconstant, i.e., each knuckle exhibits the same area, or varying, i.e.,different size cells, presenting at least two different knuckle areas.Likewise, the pillow region can be defined by the spacing between cellsas measured in either one or more directions of a coordinate referenceplane, or variable spacing between cells as measured in one or moredirections of a coordinate reference plane.

Finally, Table 1 records substrate performance parameters important tocommercially successful fibrous structures, particularly paper towels.Absorbency rate, measured as Slope of the Square Root of Time (SST), andFlexural Rigidity/Total Dry Tensile (FR/TDT), each measured according tothe test methods in the Test Methods section below, for example, areshown to be significantly improved in the present invention, asdiscussed below.

The BOUNTY® paper towel shown in FIG. 2 has a pattern of discreteknuckles and a continuous pillow region, which is the relatively lowdensity region surrounding the discrete knuckles. The cell 24 shape andcell 24 orientation are both constant in a uniform cell location. Theknuckle size varies but the pillow width (as discussed below) isconstant. Current market BOUNTY® paper towel shown in FIG. 2 has theproduct performance properties shown in Table 1. Specifically, theBOUNTY® paper towel has product performance characteristics, includingSST of 1.65 g/sec^(1/2) and FR/TDT of 0.40.

In an effort to improve the product performance properties of thecurrent BOUNTY® paper towel, the inventors designed a new pattern forthe distribution of knuckles and pillows. FIG. 4 illustrates a roll 10Aof sanitary tissue 12A produced with the new pattern, referred to hereinas INVENTION 1. FIG. 5 shows one repeat unit 16 of the pattern of themask 14A used to make the papermaking belt (not shown, but of the typeshown in FIG. 1, having the pattern of knuckles corresponding to themask of FIG. 5) that made the sanitary tissue 12A shown in FIG. 4.Again, as with the pattern above, the sanitary tissue exhibits a patternof knuckles 20 which were formed by discrete cured resin knuckles on thepapermaking belt, and which correspond to the black areas, i.e., thecells 24, of the mask 14A shown in FIG. 4.

The paper towel of INVENTION 1 differs from in-market BOUNTY® in thatthe cells are uniform-size and uniform-shape, but are spaced in apattern in which the pillow widths vary within a row of cells parallelto one axis, e.g., the X-axis as shown in FIG. 5. It is to be noted that“rows” is not be taken strictly as straight rows, but the rows could becurved, such as in a sinusoidal pattern, wavy pattern, or the like. Asshown in FIG. 5, the cell pattern for INVENTION 1 can be understood inthe context of an X-Y coordinate plane, which can also, but notnecessarily, correspond to the MD and CD directions of papermaking. Inan embodiment, the X-Y plane of the pattern shown in FIG. 4 need notalign with the MD and CD directions of papermaking. As shown in FIG. 6,the pattern of cells can be in the form of uniform repeat units that asa whole can be oriented at an angle A with respect to the MD and CDdirections of papermaking.

In an embodiment, the cells can be understood to be in rows in onedirection, e.g., the X-direction as shown in FIG. 5. The rows can beevenly and equally spaced in a direction, e.g., the Y-direction as shownin FIG. 4. The distances YD1, YD2 . . . YDn can be equal, and for cellsizes having a maximum Y-direction dimension of between 0.015 inch and0.250 inch YDn can be between 0.020 inch and 0.200 inch. Within a row,however, the uniform-size cells need not be spaced equally, but thedistances XD1, XD2 . . . XDn can vary from between about 0.010 inch toabout 0.100 inch or from between about 0.030 inch to about 0.080 inch.

The range of width values for XD1, XD2 . . . XDn can be predetermined torepeat in a uniform pattern, and can be predetermined to have a desireddistribution, including a bi-modal distribution. FIG. 7 shows anon-limiting example of a repeat pattern for XDn, with the like numbersrepresenting equal distances. In the example pattern of FIG. 7, thedimensions are: XD1=0.030 inch; XD2=0.035 inch; XD3=0.040 inch;XD4=0.045 inch; XD5=0.050 inch; XD6=0.055 inch; and, XD7=0.060 inch.

Each cell can have a maximum X-direction dimension which defines anouter boundary in the X-direction, the tangent of which can be used todetermine XDn. Likewise, each cell can have a maximum Y-directiondimension, which defines an outer boundary in the Y-direction. However,a centerline through centerpoints of the cells in an X-direction row canbe used to determine YDn. Each cell can have a maximum X-directiondimension of between about 0.015 inches and 0.250 inches and a maximumY-direction dimension of between about 0.015 inches and 0.250 inches anda two-dimensional projected area (as cells are depicted in FIG. 4), ofbetween about 0.000176 in² and 0.0625 in².

The paper towel of INVENTION 1 exhibits an absorbency rate (SST) of 2.1g/sec^(1/2), which represents a significant product performance increasefor fibrous structures used for their absorbent properties. Further, thepaper towel of INVENTION 1 exhibits a FR/TDT of 0.51, driven primarilyby an increase in flexural rigidity, which, for paper towels,contributes to the experience of being substantial in hand or sturdywhich communicates to the consumer a cloth-like nature of the product.

While the increased product performance is important, significant, andunexpected, the inventor found that when INVENTION 1 was embossed with apattern similar to that of current BOUNTY® paper towels, the overallvisual impression was not aesthetically acceptable when compared tocurrent BOUNTY® paper towels. In an effort to improve the visualappearance of a paper towel product having the improved performancecharacteristics of INVENTION 1, the inventors designed a yet another newpattern for the knuckles and pillows of a fibrous structure. FIG. 8illustrates a portion of a roll 10B of sanitary tissue 12B produced withthe new pattern, referred to herein as INVENTION 2. FIG. 9 shows arepeat unit of the mask 14B used to make the papermaking belt (notshown, but of the type shown in FIG. 1, having the pattern of knucklescorresponding to the mask of FIG. 9) that made the sanitary tissue 12Bshown in FIG. 8. Again, as with the pattern above, the sanitary tissueexhibits a pattern of knuckles 20 which were formed by discrete curedresin knuckles on the papermaking belt, and which correspond to theblack areas, i.e., cells 24 of the mask shown in FIG. 9.

INVENTION 2 differs from INVENTION 1 in that in that the uniform-sizeand uniform-shape cells are spaced in a pattern in which the pillowwidths vary within a row of cells along both of two axes, e.g., an X-Yaxis. Again, it is to be noted that “rows” is not be taken strictly asstraight rows, but the rows could be curved, such as in a sinusoidalpattern, wavy pattern, or the like. As shown in FIG. 9, the cell patternfor INVENTION 2 can be understood in the context of an X-Y coordinateplane oriented at an angle A to the MD. In an embodiment, the cells canbe understood to be in rows in two directions, e.g., the X-direction andY-direction, as shown in FIG. 8. Within both rows the uniform-size cellsare not spaced equally, but the distances XD1, XD2 . . . XDn and YD1,YD2 . . . YDn are not necessarily equal, and can vary from between about0.030 inch to about 0.080 inch. The range of width values along eitherdirection can be predetermined to repeat in a uniform pattern, and canbe predetermined to have a desired distribution, including a bi-modaldistribution. Each cell can have a maximum X-direction dimension whichdefines an outer boundary in the X-direction, the tangent of which canbe used to determine XDn. Likewise, each cell can have a maximumY-direction dimension, which defines an outer boundary in theY-direction. The cells can have a two-dimensional projected area (ascells are depicted in FIG. 9), of between about 0.000176 in² and 0.0625in².

INVENTION 2 has an improved absorbency rate (SST) (relative to in-marketBOUNTY®) of 1.97 g/sec^(1/2) and an FR/TDT value of 0.47. While theincreased absorbency and sturdiness is again important, the inventorfound that when INVENTION 2 was embossed 30 with a pattern similar tothat of current BOUNTY® paper towels, the overall visual impression wasaesthetically acceptable, and on par with current in-market BOUNTY®paper towels.

In an effort to maintain the improved absorbency properties and improvevisual appearance of a paper towel product, the inventors designed yetanother new pattern for the knuckles and pillows of a fibrous structure.FIG. 10 illustrates a roll 10C of sanitary tissue 12C produced with thenew pattern, referred to herein as INVENTION 3. FIG. 11 shows the mask14C used to make the papermaking belt (not shown, but of the type shownin FIG. 1, having the pattern of knuckles corresponding to the mask ofFIG. 11) that made the sanitary tissue 12C shown in FIG. 10. Again, aswith the pattern above, the sanitary tissue exhibits a pattern ofknuckles 20 which were formed by discrete cured resin knuckles on thepapermaking belt, and which correspond to the black areas, i.e., cells24, of the mask shown in FIG. 11.

INVENTION 3 differs from the previous embodiments in that theuniform-size and uniform-shape cells are spaced in a repeat unitexhibiting one or more generally radial patterns of cells. The repeatunit shown in FIG. 11 has two generally radial patterns. For eachgenerally radial pattern the cell pattern repeat unit can include “rows”of cells, each row being one of a series of concentric geometric shapes,which shapes can approximate a circle, as shown in FIG. 11, or othergeometric shape, as shown in FIG. 12. The space between the outerboundaries of the last row of the geometric shape can be filled with apattern of spaced apart cells in which the pillow widths betweenadjacent cells can differ within a range of about 0.030 inch to about0.080 inch.

In the cell pattern of INVENTION 3, each row of cells, e.g., R1, R2 . .. Rn is spaced at a radial distance RD1, RD2 . . . RDn, respectivelyfrom a centerpoint CP of the cell repeating pattern, such as theindicated RD distances RD4 (distance form centerpoint to Row 4) and RD6(distance from centerpoint to Row 6). The centerpoint CP can beapproximated or calculated from the digital image of the cell patternused for the mask. The distance RDn can be an average distance from thecenterpoint CP to each cell of a given row. The shortest line betweenthe side edges of adjacent cells within a row defines a distance D, andthe repeat pattern can be designed such as that the distance D betweencells within a row is equal, but the distance between cells row to rowdecreases from the inside out. That is, distance D1, which is thedistance between the side edges of adjacent cells within Row 1 isgreater than the distance D2, which is the distance between the sideedges of adjacent cells within Row 2, and so on until the last row at adistance Dn, which in the embodiment of FIG. 11 is Row 6. The distancesRDn can vary in a range from of about 0.030 inch to about 0.080 inch.Likewise, the distances D can vary within a row in a range from of about0.030 inch to about 0.080 inch.

INVENTION 3 has an improved absorbency rate (SST) (relative to in-marketBOUNTY®) of 1.91 g/sec^(1/2) and an FR/TDT value of 0.48. However, whilethe increased absorbency and sturdiness is again important, the inventorfound that when INVENTION 3 was embossed with a pattern similar to thatof current BOUNTY® paper towels, the overall visual impression was lessaesthetically acceptable than that of current in-market BOUNTY® papertowels.

Papermaking Belts

The fibrous structures of the present disclosure can be made using apapermaking belt of the type described in FIG. 1, but having knuckles inthe shape and pattern described herein. The papermaking belt can bethought of as a molding member. A “molding member” is a structuralelement having cell sizes and placement as described herein that can beused as a support for an embryonic web comprising a plurality ofcellulosic fibers and/or a plurality of synthetic fibers as well as to“mold” a desired geometry of the fibrous structures during papermaking(i.e., excluding “dry” processes such as embossing). The molding membercan comprise fluid-permeable areas and has the ability to impart athree-dimensional pattern of knuckles to the fibrous structure beingproduced thereon, and includes, without limitation, single-layer andmulti-layer structures in the class of papermaking belts having UV-curedresin knuckles on a woven reinforcing member as disclosed in the abovementioned U.S. Pat. No. 6,610,173, issued to Lindsay et al. or U.S. Pat.No. 4,514,345 issued to Trokhan.

In one embodiment, the papermaking belt is a fabric crepe belt for usein a process as disclosed in the above mentioned U.S. Pat. No.7,494,563, issued to Edwards, but having the pattern of cells, i.e.,knuckles, as disclosed herein. Fabric crepe belts can be made byextruding, coating, or otherwise applying a polymer, resin, or othercurable material onto a support member, such that the resulting patternof three-dimensional features are belt knuckles with the pillow regionsserving as large recessed pockets the fiber upon high impact creping ina creping nip between a backing roll and the fabric to form additionalbulk in conventional wet press processes. In another embodiment, thepapermaking belt can be a continuous knuckle belt of the typeexemplified in FIG. 1 of U.S. Pat. No. 4,514,345 issued to Trokhan,having deflection conduits that serve as the recessed pockets of thebelt shown and described in U.S. Pat. No. 7,494,563, for example inplace of the fabric crepe belt shown and described therein.

In an example of a method for making fibrous structures of the presentdisclosure, the method can comprise the steps of:

-   -   (a) providing a fibrous furnish comprising fibers; and    -   (b) depositing the fibrous furnish onto a molding member such        that at least one fiber is deflected out-of-plane of the other        fibers present on the molding member.

In still another example of a method for making a fibrous structure ofthe present disclosure, the method comprises the steps of:

-   -   (a) providing a fibrous furnish comprising fibers;    -   (b) depositing the fibrous furnish onto a foraminous member to        form an embryonic fibrous web;    -   (c) associating the embryonic fibrous web with a papermaking        belt having a pattern of knuckles as disclosed herein such that        at a portion of the fibers are deflected out-of-plane of the        other fibers present in the embryonic fibrous web; and    -   (d) drying said embryonic fibrous web such that that the dried        fibrous structure is formed.

In another example of a method for making the fibrous structures of thepresent disclosure, the method can comprise the steps of:

-   -   (a) providing a fibrous furnish comprising fibers;    -   (b) depositing the fibrous furnish onto a foraminous member such        that an embryonic fibrous web is formed;    -   (c) associating the embryonic web with a papermaking belt having        a pattern of knuckles as disclosed herein such that at a portion        of the fibers can be formed in the substantially continuous        deflection conduits;    -   (d) deflecting a portion of the fibers in the embryonic fibrous        web into the substantially continuous deflection conduits and        removing water from the embryonic web so as to form an        intermediate fibrous web under such conditions that the        deflection of fibers is initiated no later than the time at        which the water removal through the discrete deflection cells or        the substantially continuous deflection conduits is initiated;        and    -   (e) optionally, drying the intermediate fibrous web; and    -   (f) optionally, foreshortening the intermediate fibrous web,        such as by creping.

FIG. 13 is a simplified, schematic representation of one example of acontinuous fibrous structure making process and machine useful in thepractice of the present disclosure. The following description of theprocess and machine include non-limiting examples of process parametersuseful for making a fibrous structure of the present invention.

As shown in FIG. 13, process and equipment 150 for making fibrousstructures according to the present disclosure comprises supplying anaqueous dispersion of fibers (a fibrous furnish) to a headbox 152 whichcan be of any design known to those of skill in the art. From theheadbox 152, the aqueous dispersion of fibers can be delivered to aforaminous member 154, which can be a Fourdrinier wire, to produce anembryonic fibrous web 156.

The foraminous member 154 can be supported by a breast roll 158 and aplurality of return rolls 160 of which only two are illustrated. Theforaminous member 154 can be propelled in the direction indicated bydirectional arrow 162 by a drive means, not illustrated, at apredetermined velocity, V1. Optional auxiliary units and/or devicescommonly associated with fibrous structure making machines and with theforaminous member 154, but not illustrated, comprise forming boards,hydrofoils, vacuum boxes, tension rolls, support rolls, wire cleaningshowers, and other various components known to those of skill in theart.

After the aqueous dispersion of fibers is deposited onto the foraminousmember 154, the embryonic fibrous web 156 is formed, typically by theremoval of a portion of the aqueous dispersing medium by techniquesknown to those skilled in the art. Vacuum boxes, forming boards,hydrofoils, and other various equipment known to those of skill in theart are useful in effectuating water removal. The embryonic fibrous web156 can travel with the foraminous member 154 about return roll 160 andcan be brought into contact with a papermaking belt 164, also referredto as a papermaking belt, in a transfer zone 136, after which theembryonic fibrous web travels on the papermaking belt 164. While incontact with the papermaking belt 164, the embryonic fibrous web 156 canbe deflected, rearranged, and/or further dewatered.

The papermaking belt 164 can be in the form of an endless belt. In thissimplified representation, the papermaking belt 164 passes around andabout papermaking belt return rolls 166 and impression nip roll 168 andcan travel in the direction indicated by directional arrow 170, at apapermaking belt velocity V2, which can be less than, equal to, orgreater than, the foraminous member velocity V1. In the presentinvention papermaking belt velocity V2 is less than foraminous membervelocity V1 such that the partially-dried fibrous web is foreshortenedin the transfer zone 136 by a percentage determined by the relativevelocity differential between the foraminous member and the papermakingbelt. Associated with the papermaking belt 164, but not illustrated, canbe various support rolls, other return rolls, cleaning means, drivemeans, and other various equipment known to those of skill in the artthat may be commonly used in fibrous structure making machines.

The papermaking belts 164 of the present disclosure can be made, orpartially made, according to the process described in U.S. Pat. No.4,637,859, issued Jan. 20, 1987, to Trokhan, and having the patterns ofcells as disclosed herein.

The fibrous web 192 can then be creped with a creping blade 194 toremove the web 192 from the surface of the Yankee dryer 190 resulting inthe production of a creped fibrous structure 196 in accordance with thepresent disclosure. As used herein, creping refers to the reduction inlength of a dry (having a consistency of at least about 90% and/or atleast about 95%) fibrous web which occurs when energy is applied to thedry fibrous web in such a way that the length of the fibrous web isreduced and the fibers in the fibrous web are rearranged with anaccompanying disruption of fiber-fiber bonds. Creping can beaccomplished in any of several ways as is well known in the art. Thecreped fibrous structure 196 is wound on a reel, commonly referred to asa parent roll, and can be subjected to post processing steps such ascalendaring, tuft generating operations, embossing, and/or converting.The reel winds the creped fibrous structure at a reel surface velocity,V4.

The papermaking belts of the present disclosure can be utilized to formdiscrete elements and a substantially continuous network into a fibrousstructure during a through-air-drying operation. The discrete elementscan be knuckles and can be relatively high density relative to thecontinuous network, which can be a continuous pillow having a relativelylower density.

As discussed above, the fibrous structure can be embossed during aconverting operating to produce the embossed fibrous structures of thepresent disclosure.

An example of fibrous structures in accordance with the presentdisclosure can be prepared using a papermaking machine as describedabove with respect to FIG. 13, and according to the method describedbelow.

A 3% by weight aqueous slurry of northern softwood kraft (NSK) pulp ismade up in a conventional re-pulper. The NSK slurry is refined gentlyand a 2% solution of a permanent wet strength resin (i.e. Kymene 5221marketed by Hercules incorporated of Wilmington, Del.) is added to theNSK stock pipe at a rate of 1% by weight of the dry fibers. Kymene 5221is added as a wet strength additive. The adsorption of Kymene 5221 toNSK is enhanced by an in-line mixer. A 1% solution of Carboxy MethylCellulose (CMC) (i.e. FinnFix 700 marketed by C.P. Kelco U.S. Inc. ofAtlanta, Ga.) is added after the in-line mixer at a rate of 0.2% byweight of the dry fibers to enhance the dry strength of the fibroussubstrate. A 3% by weight aqueous slurry of hardwood Eucalyptus fibersis made up in a conventional re-pulper. A 1% solution of defoamer (i.e.BuBreak 4330 marketed by Buckman Labs, Memphis TS) is added to theEucalyptus stock pipe at a rate of 0.25% by weight of the dry fibers andits adsorption is enhanced by an in-line mixer.

The NSK furnish and the Eucalyptus fibers are combined in the head boxand deposited onto a Fourdrinier wire, running at a first velocity V₁,homogenously to form an embryonic web. The web is then transferred atthe transfer zone from the Fourdrinier forming wire at a fiberconsistency of about 15% to the papermaking belt, the papermaking beltmoving at a second velocity, V₂. The papermaking belt has a pattern ofdiscrete raised portions extending from a reinforcing member, discreteraised portions defining a substantially continuous deflection conduitportion, as described herein, particularly with reference to FIGS. 13Ato 16. The transfer occurs in the transfer zone without precipitatingsubstantial densification of the web. The web is then forwarded, at thesecond velocity, V₂, on the papermaking belt along a looped path incontacting relation with a transfer head disposed at the transfer zone,the second velocity being from about 1% to about 40% slower than thefirst velocity, V₁. Since the Fourdrinier wire speed is faster than thepapermaking belt, wet shortening, i.e., foreshortening, of the weboccurs at the transfer point. In an embodiment the second velocity V₂can be from about 0% to about 5% faster than the first velocity V₁.

Further de-watering is accomplished by vacuum assisted drainage untilthe web has a fiber consistency of about 15% to about 30%. The patternedweb is pre-dried by air blow-through, i.e., through-air-drying (TAD), toa fiber consistency of about 65% by weight. The web is then adhered tothe surface of a Yankee dryer with a sprayed creping adhesive comprising0.25% aqueous solution of polyvinyl alcohol (PVA). The fiber consistencyis increased to an estimated 95%-97% before dry creping the web with adoctor blade. The doctor blade has a bevel angle of about 45 degrees andis positioned with respect to the Yankee dryer to provide an impactangle of about 101 degrees. This doctor blade position permits theadequate amount of force to be applied to the substrate to remove it offthe Yankee while minimally disturbing the previously generated webstructure. The dried web is reeled onto a take up roll (known as aparent roll), the surface of the take up roll moving at a fourthvelocity, V₄, that is faster than the third velocity, V₃, of the Yankeedryer. By reeling at a fourth velocity, V₄, that is about 1% to 20%faster than the third velocity, V₃, some of the foreshortening providedby the creping step is “pulled out,” sometimes referred to as a“positive draw,” so that the paper can be more stable for any furtherconverting operations.

Two plies of the web can be formed into paper towel products byembossing and laminating them together using PVA adhesive. The papertowel has about 53 g/m² basis weight and contains 65% by weight NorthernSoftwood Kraft and 35% by weight Eucalyptus furnish.

The sanitary tissue product is soft, flexible and absorbent.

Another advantage of certain designs of the present invention relate toa problem common in web handling, referred to as “edge curl.” When aspan of substrate, such as a fibrous substrate of cellulosic tissue isbeing processed under tension at commercial rates, the edges can riseout of plane in a way that interferes with desired processing. This edgecurl is particularly a problem for relatively higher caliper products,such as absorbent tissue substrates for paper towel products.

The inventors have found that one driver of the edge curl phenomenon isthe distribution of forces in the web that are transmitted through thecontinuous feature, such as a continuous knuckle region or a continuouspillow region. In particular, the inventors found that for a substrateweb having a caliper of about 23 mils and continuous pillow regions edgecurl reduction or elimination can be achieved by ensuring the length ofthe pillow between any two knuckles measured in the CD direction at anypoint along the MD direction (i.e., pillow width, PW) is less than about158 mils (less than about 0.158 inch). For patterns such as the patternshown in FIG. 5, in which there are spans between rows of knuckles inwhich the pillow distance is effectively infinite (extending from oneedge of the substrate to the other, uninterrupted by a knuckle), theinventors found the mask can be designed such that the entire pattern ofknuckles can be rotated at an angle such that X-axis of the pattern isat an angle to the CD sufficiently such that there is no uninterruptedpillow in the CD, and the length of pillow between any two knucklesmeasured in the CD direction at any point along the MD direction is lessthan about 158 mils. In an embodiment, the angle of the X-axis withrespect to the CD can be from about ±1 degree to about 25 degrees.

Table 2 shows some representative patterns for continuous pillows on aweb substrate and the effect of pillow width PW on edge curl. As can beseen, patterns that are designed with relatively short pillow widths PWat zero rotation no edge curl is observed. And patterns that aredesigned with infinite pillow widths PW at zero rotation can achievelittle or no edge curl when rotated to reduce the pillow width to lessthan about 158 mils.

TABLE 2 Edge Curl Reduction Cell Min. Edge Sample count/ cell sizeRotation CD PW (mil) Curl Product in{circumflex over ( )}2 (mil) (deg.)shortest longest Reduced In Market 133 42 × 65 0 49 Infinite No Bounty133 42 × 65 25 39 119 Yes Embodiment 1 160 42 × 65 4 43 Infinite No 16042 × 65 18 44 130 Yes Embodiment 2 133 42 × 65 0 32 76 Yes approx.Embodiment 3 155 45 × 45 25 36 155 Yes Embodiment 4 141 42 × 65 3 13Infinite No Embodiment 5 133 42 × 65 1 47 689 No Embodiment 6 150 39 ×62 18 47 158 Yes

Test Methods

Unless otherwise specified, all tests described herein including thosedescribed under the Definitions section and the following test methodsare conducted on samples that have been conditioned in a conditionedroom at a temperature of 73° F.±4° F. (about 23° C.±2.2° C.) and arelative humidity of 50%±10% for 2 hours prior to the test. If thesample is in roll form, remove the first 35 to about 50 inches of thesample by unwinding and tearing off via the closest perforation line, ifone is present, and discard before testing the sample. All plastic andpaper board packaging materials must be carefully removed from the papersamples prior to testing. Discard any damaged product. All tests areconducted in such conditioned room.

Flexural Rigidity Test Method

This test is performed on 1 inch×6 inch (2.54 cm×15.24 cm) strips of afibrous structure sample. A Cantilever Bending Tester such as describedin ASTM Standard D 1388 (Model 5010, Instrument Marketing Services,Fairfield, N.J.) is used and operated at a ramp angle of 41.5±0.5° and asample slide speed of 0.5±0.2 in/second (1.3±0.5 cm/second). A minimumof n=16 tests are performed on each sample from n=8 sample strips.

No fibrous structure sample which is creased, bent, folded, perforated,or in any other way weakened should ever be tested using this test. Anon-creased, non-bent, non-folded, non-perforated, and non-weakened inany other way fibrous structure sample should be used for testing underthis test.

From one fibrous structure sample of about 4 inch×6 inch (10.16 cm×15.24cm), carefully cut using a 1 inch (2.54 cm) JDC Cutter (available fromThwing-Albert Instrument Company, Philadelphia, Pa.) four (4) 1 inch(2.54 cm) wide by 6 inch (15.24 cm) long strips of the fibrous structurein the MD direction. From a second fibrous structure sample from thesame sample set, carefully cut four (4) 1 inch (2.54 cm) wide by 6 inch(15.24 cm) long strips of the fibrous structure in the CD direction. Itis important that the cut be exactly perpendicular to the long dimensionof the strip. In cutting non-laminated two-ply fibrous structure strips,the strips should be cut individually. The strip should also be free ofwrinkles or excessive mechanical manipulation which can impactflexibility. Mark the direction very lightly on one end of the strip,keeping the same surface of the sample up for all strips. Later, thestrips will be turned over for testing, thus it is important that onesurface of the strip be clearly identified, however, it makes nodifference which surface of the sample is designated as the uppersurface.

Using other portions of the fibrous structure (not the cut strips),determine the basis weight of the fibrous structure sample in lbs/3000ft² and the caliper of the fibrous structure in mils (thousandths of aninch) using the standard procedures disclosed herein. Place theCantilever Bending Tester level on a bench or table that is relativelyfree of vibration, excessive heat and most importantly air drafts.Adjust the platform of the Tester to horizontal as indicated by theleveling bubble and verify that the ramp angle is at 41.5±0.5°. Removethe sample slide bar from the top of the platform of the Tester. Placeone of the strips on the horizontal platform using care to align thestrip parallel with the movable sample slide. Align the strip exactlyeven with the vertical edge of the Tester wherein the angular ramp isattached or where the zero mark line is scribed on the Tester. Carefullyplace the sample slide bar back on top of the sample strip in theTester. The sample slide bar must be carefully placed so that the stripis not wrinkled or moved from its initial position.

Move the strip and movable sample slide at a rate of approximately0.5±0.2 in/second (1.3±0.5 cm/second) toward the end of the Tester towhich the angular ramp is attached. This can be accomplished with eithera manual or automatic Tester. Ensure that no slippage between the stripand movable sample slide occurs. As the sample slide bar and stripproject over the edge of the Tester, the strip will begin to bend, ordrape downward. Stop moving the sample slide bar the instant the leadingedge of the strip falls level with the ramp edge. Read and record theoverhang length from the linear scale to the nearest 0.5 mm. Record thedistance the sample slide bar has moved in cm as overhang length. Thistest sequence is performed a total of eight (8) times for each fibrousstructure in each direction (MD and CD). The first four strips aretested with the upper surface as the fibrous structure was cut facingup. The last four strips are inverted so that the upper surface as thefibrous structure was cut is facing down as the strip is placed on thehorizontal platform of the Tester.

The average overhang length is determined by averaging the sixteen (16)readings obtained on a fibrous structure.

${{Overhang}\mspace{14mu} {Length}\mspace{14mu} {MD}} = \frac{{Sum}\mspace{14mu} {of}\mspace{14mu} 8\mspace{14mu} {MD}\mspace{14mu} {readings}}{8}$${{Overhang}\mspace{14mu} {Length}\mspace{14mu} {CD}} = \frac{{Sum}\mspace{14mu} {of}\mspace{14mu} 8\mspace{14mu} {CD}\mspace{14mu} {readings}}{8}$${{Overhang}\mspace{14mu} {Length}\mspace{14mu} {Total}} = \frac{{Sum}\mspace{14mu} {of}\mspace{14mu} {all}\mspace{14mu} 16\mspace{14mu} {readings}}{16}$${{Bend}\mspace{14mu} {Length}\mspace{14mu} {MD}} = \frac{{Overhang}\mspace{14mu} {Length}\mspace{14mu} {MD}}{2}$${{Bend}\mspace{14mu} {Length}\mspace{14mu} {CD}} = \frac{{Overhang}\mspace{14mu} {Length}\mspace{14mu} {CD}}{2}$${{Bend}\mspace{14mu} {Length}\mspace{14mu} {Total}} = \frac{{Overhang}\mspace{14mu} {Length}\mspace{14mu} {Total}}{2}$Flexural  Rigidity = 0.1628 × W × C³

wherein W is the basis weight of the fibrous structure in lbs/3000 ft²;C is the bending length (MD or CD or Total) in cm; and the constant0.1629 is used to convert the basis weight from English to metric units.The results are expressed in mg*cm²/cm (or alternatively mg*cm).

GM Flexural Rigidity=Square root of (MD Flexural Rigidity×CD FlexuralRigidity).

Basis Weight Test Method

Basis weight of a fibrous structure sample is measured by selectingtwelve (12) usable units (also referred to as sheets) of the fibrousstructure and making two stacks of six (6) usable units each.Perforation must be aligned on the same side when stacking the usableunits. A precision cutter is used to cut each stack into exactly 8.89cm×8.89 cm (3.5 in.×3.5 in.) squares. The two stacks of cut squares arecombined to make a basis weight pad of twelve (12) squares thick. Thebasis weight pad is then weighed on a top loading balance with a minimumresolution of 0.01 g. The top loading balance must be protected from airdrafts and other disturbances using a draft shield. Weights are recordedwhen the readings on the top loading balance become constant. The BasisWeight is calculated as follows:

${{Basis}\mspace{14mu} {Weight}\mspace{14mu} \left( {{lbs}\text{/}3000\mspace{14mu} {ft}^{2}} \right)} = \frac{{Weight}\mspace{14mu} {of}\mspace{14mu} {basis}\mspace{14mu} {weight}\mspace{14mu} {pad}\mspace{14mu} (g) \times 3000\mspace{14mu} {ft}^{2}}{\begin{matrix}{453.6\mspace{14mu} g\text{/}{lbs} \times 12\mspace{14mu} \left( {{usable}\mspace{14mu} {units}} \right) \times} \\\left\lbrack {12.25\mspace{14mu} {{{in}^{2}\mspace{14mu}\left( {{Area}\mspace{14mu} {of}\mspace{14mu} {basis}\mspace{14mu} {weight}\mspace{14mu} {pad}} \right)}/144}\mspace{14mu} {in}^{2}} \right\rbrack\end{matrix}}$${{Basis}\mspace{14mu} {Weight}\mspace{14mu} \left( {g\text{/}m^{2}\mspace{14mu} {or}\mspace{14mu} {gsm}} \right)} = \frac{{Weight}\mspace{14mu} {of}\mspace{14mu} {basis}\mspace{14mu} {weight}\mspace{14mu} {pad}\mspace{14mu} (g) \times 10,000\mspace{14mu} {cm}^{2}\text{/}m^{2}}{79.0321\mspace{14mu} {cm}^{2}\mspace{14mu} \left( {{Area}\mspace{14mu} {of}\mspace{14mu} {basis}\mspace{14mu} {weight}\mspace{14mu} {pad}} \right) \times 12\mspace{14mu} \left( {{usable}\mspace{14mu} {units}} \right)}$

Caliper Test Method

Caliper of a fibrous structure is measured by cutting five (5) samplesof fibrous structure such that each cut sample is larger in size than aload foot loading surface of a VIR Electronic Thickness Tester Model IIavailable from Thwing-Albert Instrument Company, Philadelphia, Pa.Typically, the load foot loading surface has a circular surface area ofabout 3.14 in². The sample is confined between a horizontal flat surfaceand the load foot loading surface. The load foot loading surface appliesa confining pressure to the sample of 95 g/in². The caliper of eachsample is the resulting gap between the flat surface and the load footloading surface. The caliper is calculated as the average caliper of thefive samples. The result is reported in thousandths of an inch (mils).

Elongation, Tensile Strength, TEA and Modulus Test Methods

Remove four (4) usable units (also referred to as sheets) of fibrousstructures and stack one on top of the other to form a long stack withthe perforations between the sheets coincident. Identify sheets 1 and 3for machine direction tensile measurements and sheets 2 and 4 for crossdirection tensile measurements. Next, cut through the perforation lineusing a paper cutter (JDC-1-10 or JDC-1-12 with safety shield fromThwing-Albert Instrument Co. of Philadelphia, Pa.) to make 4 separatestacks. Make sure stacks 1 and 3 are still identified for machinedirection testing and stacks 2 and 4 are identified for cross directiontesting.

Cut two 1 inch (2.54 cm) wide strips in the machine direction fromstacks 1 and 3. Cut two 1 inch (2.54 cm) wide strips in the crossdirection from stacks 2 and 4. There are now four 1 inch (2.54 cm) widestrips for machine direction tensile testing and four 1 inch (2.54 cm)wide strips for cross direction tensile testing.

For the actual measurement of the elongation, tensile strength, TEA andmodulus, use a Thwing-Albert Intelect II Standard Tensile Tester(Thwing-Albert Instrument Co. of Philadelphia, Pa.). Insert the flatface clamps into the unit and calibrate the tester according to theinstructions given in the operation manual of the Thwing-Albert IntelectII. Set the instrument crosshead speed to 4.00 in/min (10.16 cm/min) andthe gauge length to 4.00 inches (10.16 cm). The break sensitivity is setto 20.0 grams and the sample width is set to 1.00 inch (2.54 cm) and thesample thickness is set to 0.3937 inch (1 cm). The energy units are setto TEA and the tangent modulus (Modulus) trap setting is set to 38.1 g.

Take one of the fibrous structure sample strips and place one end of itin one clamp of the tensile tester. Place the other end of the fibrousstructure sample strip in the other clamp. Make sure the long dimensionof the fibrous structure sample strip is running parallel to the sidesof the tensile tester. Also make sure the fibrous structure samplestrips are not overhanging to the either side of the two clamps. Inaddition, the pressure of each of the clamps must be in full contactwith the fibrous structure sample strip.

After inserting the fibrous structure sample strip into the two clamps,the instrument tension can be monitored. If it shows a value of 5 gramsor more, the fibrous structure sample strip is too taut. Conversely, ifa period of 2-3 seconds passes after starting the test before any valueis recorded, the fibrous structure sample strip is too slack.

Start the tensile tester as described in the tensile tester instrumentmanual. The test is complete after the crosshead automatically returnsto its initial starting position. When the test is complete, read andrecord the following with units of measure:

Peak Load Tensile (Tensile Strength) (g/in)

Peak Elongation (Elongation) (%)

Peak TEA (TEA) (in-g/in²)

Tangent Modulus (Modulus) (at 15 g/cm)

Test each of the samples in the same manner, recording the abovemeasured values from each test.

Calculations:

Geometric Mean (GM) Elongation=Square Root of [MD Elongation (%)×CDElongation (%)]

Total Dry Tensile (TDT)=Peak Load MD Tensile (g/in)+Peak Load CD Tensile(g/in)

Tensile Ratio=Peak Load MD Tensile (g/in)/Peak Load CD Tensile (g/in)

Geometric Mean (GM) Tensile=[Square Root of (Peak Load MD Tensile(g/in)×Peak Load CD Tensile (g/M))]×3

TEA=MD TEA (in-g/in²)+CD TEA (in-g/in²)

Geometric Mean (GM) TEA=Square Root of [MD TEA (in-g/in²)×CD TEA(in-g/in²)]

Modulus=MD Modulus (at 15 g/cm)+CD Modulus (at 15 g/cm)

Geometric Mean (GM) Modulus=Square Root of [MD Modulus (at 15 g/cm)×CDModulus (at 15 g/cm)]

Tensile Tester Settings for a 5000 Gram Load Cell (Settings Shown forEnglish Units) EJA 1000/EJA 2000

Product Setting Units Tissue/Napkins Facials Towels Set Mode TensionTension Tension English/Metric English English English Curve Unitsload/elong load/elong load/elong Energy Units TEA TEA TEA ElongationUnits ins ins ins Load Units gms gms gms Test Over Fail Fail Fail SetRange 100% 100% 100% At Test End Return Return Return Pre/Test Speedins/min 4.00 6.00 4.00 Test Speed ins/min 4.00 6.00 4.00 Start of TestSpeed ins/min 4.00 6.00 4.00 Start of Test Distance ins 0.1 0.1 0.1Post-Change Speed ins/min 4.00 6.00 4.00 Return Speed ins/min 20 or 4020 or 40 20 or 40 Sampling Rate 20 20 20 Chart Device Collision yes yesyes 1st Gauge Length ins — — — 2nd Gauge Length ins — — — Gauge Lengthins 2.00 4.00 4.00 Adj. Gauge Length Adj. Adj. Adj. Break Sensitivitygms 20 20 20 Pre-tension* 11.12/2.22/1.39 11.12/1.39 11.12 Sample Size —— — Load divider Table 1 Table 1 Table 1 Sample Shape RectangleRectangle Rectangle Sample Width ins 1.00 1.00 1.00 Sample Thickness ins0.3937 0.3937 0.3937 Set Start Load 0 0 0 Set Zero Load 0.05 0.05 0.05

SST Absorbency Rate

This test incorporates the Slope of the Square Root of Time (SST) TestMethod.

The SST method measures rate over a wide spectrum of time to capture aview of the product pick-up rate over the useful lifetime. Inparticular, the method measures the absorbency rate via the slope of themass versus the square root of time from 2-15 seconds.

Overview

The absorption (wicking) of water by a fibrous sample is measured overtime. A sample is placed horizontally in the instrument and is supportedby an open weave net structure that rests on a balance. The test isinitiated when a tube connected to a water reservoir is raised and themeniscus makes contact with the center of the sample from beneath, at asmall negative pressure. Absorption is controlled by the ability of thesample to pull the water from the instrument for approximately 20seconds. Rate is determined as the slope of the regression line of theoutputted weight vs sqrt(time) from 2 to 15 seconds.

Apparatus

-   -   Conditioned Room—Temperature is controlled from 73° F.+2° F.        (23° C.+1° C.). Relative Humidity is controlled from 50%±2%    -   Sample Preparation—Product samples are cut using        hydraulic/pneumatic precision cutter into 3.375 inch diameter        circles.    -   Capacity Rate Tester (CRT)—The CRT is an absorbency tester        capable of measuring capacity and rate. The CRT consists of a        balance (0.001 g), on which rests on a woven grid (using nylon        monofilament line having a 0.014″ diameter) placed over a small        reservoir with a delivery tube in the center. This reservoir is        filled by the action of solenoid valves, which help to connect        the sample supply reservoir to an intermediate reservoir, the        water level of which is monitored by an optical sensor. The CRT        is run with a −2 mm water column, controlled by adjusting the        height of water in the supply reservoir.    -   Software—LabView based custom software specific to CRT Version        4.2 or later.    -   Water—Distilled water with conductivity <10 μS/cm (target <5        μS/cm) @ 25° C.

Sample Preparation

For this method, a usable unit is described as one finished product unitregardless of the number of plies. Condition all samples with packagingmaterials removed for a minimum of 2 hours prior to testing. Discard atleast the first ten usable units from the roll. Remove two usable unitsand cut one 3.375-inch circular sample from the center of each usableunit for a total of 2 replicates for each test result. Do not testsamples with defects such as wrinkles, tears, holes, etc. Replace withanother usable unit which is free of such defects

Sample Testing

Pre-Test Set-Up

-   -   1. The water height in the reservoir tank is set −2.0 mm below        the top of the support rack (where the towel sample will be        placed).    -   2. The supply tube (8 mm I.D.) is centered with respect to the        support net.    -   3. Test samples are cut into circles of 3⅜″ diameter and        equilibrated at Tappi environment conditions for a minimum of 2        hours.

Test Description

-   -   1. After pressing the start button on the software application,        the supply tube moves to 0.33 mm below the water height in the        reserve tank. This creates a small meniscus of water above the        supply tube to ensure test initiation. A valve between the tank        and the supply tube closes, and the scale is zeroed.    -   2. The software prompts you to “load a sample”. A sample is        placed on the support net, centering it over the supply tube,        and with the side facing the outside of the roll placed        downward.    -   3. Close the balance windows, and press the “OK” button—the        software records the dry weight of the circle.    -   4. The software prompts you to “place cover on sample”. The        plastic cover is placed on top of the sample, on top of the        support net. The plastic cover has a center pin (which is flush        with the outside rim) to ensure that the sample is in the proper        position to establish hydraulic connection. Four other pins, 1        mm shorter in depth, are positioned 1.25-1.5 inches radially        away from the center pin to ensure the sample is flat during the        test. The sample cover rim should not contact the sheet. Close        the top balance window and click “OK”.    -   5. The software re-zeroes the scale and then moves the supply        tube towards the sample. When the supply tube reaches its        destination, which is 0.33 mm below the support net, the valve        opens (i.e., the valve between the reserve tank and the supply        tube), and hydraulic connection is established between the        supply tube and the sample. Data acquisition occurs at a rate of        5 Hz, and is started about 0.4 seconds before water contacts the        sample.    -   6. The test runs for at least 20 seconds. After this, the supply        tube pulls away from the sample to break the hydraulic        connection.    -   7. The wet sample is removed from the support net. Residual        water on the support net and cover are dried with a paper towel.    -   8. Repeat until all samples are tested.    -   9. After each test is run, a *.txt file is created (typically        stored in the CRT/data/rate directory) with a file name as typed        at the start of the test. The file contains all the test set-up        parameters, dry sample weight, and cumulative water absorbed (g)        vs. time (sec) data collected from the test.

Calculation of Rate of Uptake

Take the raw data file that includes time and weight data.

First, create a new time column that subtracts 0.4 seconds from the rawtime data to adjust the raw time data to correspond to when initiationactually occurs (about 0.4 seconds after data collection begins).

Second, create a column of data that converts the adjusted time data tosquare root of time data (e.g., using a formula such as SQRT( ) withinExcel).

Third, calculate the slope of the weight data vs the square root of timedata (e.g., using the SLOPE( ) function within Excel, using the weightdata as the y-data and the sqrt(time) data as the x-data, etc.). Theslope should be calculated for the data points from 2 to 15 seconds,inclusive (or 1.41 to 3.87 in the sqrt(time) data column)

Calculation of Slope of the Square Root of Time (SST)

The start time of water contact with the sample is estimated to be 0.4seconds after the start of hydraulic connection is established betweenthe supply tube and the sample (CRT Time). This is because dataacquisition begins while the tube is still moving towards the sample,and incorporates the small delay in scale response. Thus, “time zero” isactually at 0.4 seconds in CRT Time as recorded in the *.txt file.

The slope of the square root of time (SST) from 2-15 seconds iscalculated from the slope of a linear regression line from the squareroot of time between (and including) 2 to 15 seconds (x-axis) versus thecumulative grams of water absorbed. The units are g/sec^(0.5).

Reporting Results

Report the average slope to the nearest 0.01 g/s^(0.5).

In the interests of brevity and conciseness, any ranges of values setforth in this specification are to be construed as written descriptionsupport for claims reciting any sub-ranges having endpoints which arewhole number values within the specified range in question. By way of ahypothetical illustrative example, a disclosure in this specification ofa range of 1-5 shall be considered to support claims to any of thefollowing sub-ranges: 1-4; 1-3; 1-2; 2-5; 2-4; 2-3; 3-5; 3-4; and 4-5.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany embodiment disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such embodiment. Further, to the extent that any meaningor definition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present disclosure have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the present disclosure. It istherefore intended to cover in the appended claims all such changes andmodifications that are within the scope of this disclosure.

What is claimed is:
 1. A papermaking belt, comprising: a reinforcingelement comprising a surface; a plurality of discrete knuckles extendingfrom portions of the surface of the reinforcing element, wherein theplurality of discrete knuckles are arranged in a pattern of repeatunits, and wherein the discrete knuckles are characterized by: each ofthe discrete knuckles within the repeat unit have substantially the sameshape, each of the discrete knuckles within a repeat unit havesubstantially the same size; and wherein at least some of the discreteknuckles are arranged in a plurality of rows of adjacent knucklesseparated by a distance, and including at least a first row and a secondrow, with the distance between at least two adjacent discrete knucklesin the first row being different than the distance between at least twoadjacent discrete knuckles in the second row.
 2. The papermaking belt ofclaim 1, wherein all of the discrete knuckles are in one of theplurality of rows.
 3. The papermaking belt of claim 1, wherein all therows are oriented along one of either a Y-axis or an X-axis.
 4. Thepapermaking belt of claim 1, wherein one or more rows are oriented alonga Y-axis and one or more are oriented along an X-axis.
 5. Thepapermaking belt of claim 1, wherein the discrete knuckles are curedresin.
 6. The papermaking belt of claim 1, wherein the discrete knucklesare polymeric deposits.
 7. The papermaking belt of claim 1, wherein thereinforcing element is a woven, porous web.
 8. The papermaking belt ofclaim 1, wherein the discrete knuckles define an interconnectedplurality of surround areas.
 9. The papermaking belt of claim 1, whereinthe discrete knuckles define a plurality of deflection conduits.
 10. Apapermaking belt, comprising: a reinforcing element comprising asurface; a plurality of discrete knuckles extending from portions of thesurface of the reinforcing element, wherein the plurality of discreteknuckles are arranged in a pattern of repeat units, the repeat unitincluding a plurality of spaced apart rows, each row having a portion ofthe discrete knuckles, and wherein the discrete knuckles arecharacterized by: each of the discrete knuckles within the repeat unithave substantially the same shape, each of the discrete knuckles withina repeat unit have substantially the same size; and wherein the discreteknuckles in each row are spaced from adjacent discrete knuckles in anon-uniform manner such that the repeat unit exhibits varying pillowwidths along the row.
 11. The papermaking belt of claim 10, wherein thevarying pillow widths vary from between about 0.030 inch to about 0.060inch.
 12. The papermaking belt of claim 10, wherein the rows arenon-linear.
 13. The papermaking belt of claim 10, wherein all of thediscrete knuckles are in one of the plurality of spaced apart rows. 14.The papermaking belt of claim 10, wherein all the rows are orientedalong one of either a Y-axis or an X-axis.
 15. The papermaking belt ofclaim 10, wherein the discrete knuckles are cured resin.
 16. Thepapermaking belt of claim 10, wherein the discrete knuckles arepolymeric deposits.
 17. The papermaking belt of claim 10, wherein thereinforcing element is a woven, porous web.
 18. The papermaking belt ofclaim 10, wherein the discrete knuckles define an interconnectedplurality of surround areas.
 19. The papermaking belt of claim 10,wherein the discrete knuckles define a plurality of deflection conduits.20. A papermaking belt, comprising: a. a reinforcing element comprisinga surface; and b. a plurality of discrete knuckles arranged in a patternof repeat units, and characterized by: each of the discrete knuckleswithin the repeat unit have substantially the same shape, each of thediscrete knuckles within a repeat unit have substantially the same size;and wherein at least some of the discrete knuckles are arranged in aplurality of rows of adjacent knuckles separated by a distance, andincluding at least a first row and a second row, with the distancebetween at least two adjacent discrete knuckles in the first row beingdifferent than the distance between at least two adjacent discreteknuckles in the second row, and wherein rows are oriented along anX-axis which is at an angle between 1 degree and 25 degrees with respectto an MD direction of the fibrous structure.